Trunk as stiffening element

ABSTRACT

A stiffening element to protect against a side or frontal impact for an electric vehicle includes a first longitudinal support beam and a second longitudinal support beam. A trunk of the electric vehicle is positioned between the first longitudinal support beam and the second longitudinal support beam. The trunk is positioned between a front bumper and a firewall of the electric vehicle. The trunk includes a trunk base forming a floor of the trunk. The trunk base includes one or more stiffening elements positioned across one or both of a width or length of the trunk base.

CROSS-REFERENCE TO RELATED APPLICATION

This application a U.S. continuation of U.S. patent application Ser. No.15/696,937 filed Sep. 6, 2017, which claims the benefit of U.S.Provisional Application No. 62/384,298, filed Sep. 7, 2016, the entirecontents of which are hereby incorporated by reference for all purposes.

BACKGROUND OF THE INVENTION

There are many problems unique to electric vehicles, oftentimes due tothe presence of large and/or numerous batteries used to power theelectric motor and other components of the vehicle. These batteries areoften bulky, and add significant weight to the vehicles. Theseconsiderations present challenges in designing a particularly efficientand practical electrical vehicle. Additionally, these batteries may beparticularly susceptible to damage during a collision. Damage to abattery may be especially dangerous by presenting a fire and/orcorrosive hazard. As such, protecting the batteries from damage remainsa difficult challenge unique to the field of electric vehicles.

Vehicle manufacturers have added a number of new structural features tovehicles to improve safety and/or performance. Many of these structuralfeatures are applicable to electric, hybrid, and non-electric vehiclesequally, while others place a greater emphasis on the vehicle motortype, such as a vehicle base plate with increased thickness forprotecting an electric car battery over a specific region of thevehicle. Structural improvements that increase either safety orperformance without a significant compromise of the other remainimportant objectives of vehicle manufacturers.

Electric vehicles are becoming an increasingly viable alternative totraditional vehicles with internal combustion engines. Electric vehiclesmay have advantages in their compactness, simplicity of design, and inbeing potentially more environmentally friendly depending on the meansby which the electricity used in the vehicle was originally generated.The prospect of using renewable energy sources to power automobiles inplace of gasoline has obvious advantages as oil reserves across theglobe become increasingly depleted.

BRIEF SUMMARY OF THE INVENTION

In one aspect, a stiffening element to protect against a side or frontalimpact for an electric vehicle is provided. The stiffening element mayinclude a first longitudinal crash beam, a second longitudinal crashbeam, and a trunk of the electric vehicle positioned between the firstlongitudinal crash beam and the second longitudinal crash beam. Thetrunk may be positioned between a front bumper and a firewall of theelectric vehicle. The trunk may include a trunk base forming a floor ofthe trunk. The trunk base may include one or more stiffening elementspositioned across one or both of a width or length of the trunk base.

In another aspect, a stiffening element to protect against a side orfrontal impact for an electric vehicle may include a first longitudinalcrash beam, a second longitudinal crash beam, and a trunk of theelectric vehicle positioned between the first longitudinal crash beamand the second longitudinal crash beam. The trunk may define a storagecompartment between a front bumper and a firewall of the electricvehicle. The trunk may include a hinged trunk hood configured to provideaccess to the storage compartment. The trunk may include a trunk baseforming a floor of the trunk. The trunk base may include a support beamextending across a width of the trunk base. The support beam may beconfigured to stiffen the trunk in the event of a side impact. Thesupport beam may be positioned proximate a rear wall of the trunk.

In another aspect, a method of stiffening an electric vehicle to protectagainst a side or frontal impact for an electric vehicle is provided.The method may include positioning a trunk between a first longitudinalcrash beam and a second longitudinal crash beam of the electric vehicle.The trunk may define a storage compartment forward of a firewall of theelectric vehicle and behind a front bumper of the electric vehicle. Thetrunk may include a trunk base forming a floor of the trunk. The methodmay also include positioning a trunk support beam across a width of thetrunk base such that a first end of the trunk support beam contacts thefirst longitudinal crash beam and a second end of the trunk support beamcontacts the second longitudinal crash beam. The trunk support beam maybe configured to stiffen the trunk in the event of a side impact.

BRIEF DESCRIPTION OF THE DRAWINGS

A further understanding of the nature and advantages of variousembodiments may be realized by reference to the following figures. Inthe appended figures, similar components or features may have the samereference label. Further, various components of the same type may bedistinguished by following the reference label by a dash and a secondlabel that distinguishes among the similar components. If only the firstreference label is used in the specification, the description isapplicable to any one of the similar components having the same firstreference label irrespective of the second reference label.

FIG. 1 depicts an electric vehicle according to embodiments.

FIG. 2 depicts a top view of a power system of an electric vehicleaccording to embodiments.

FIG. 3 depicts an isometric view of a tunnel of an electric vehicleaccording to embodiments.

FIG. 4 depicts a cross-section view the tunnel of FIG. 3 according toembodiments.

FIG. 5 depicts a front cross-section view of the tunnel of FIG. 3according to embodiments.

FIG. 6 depicts a side cross-section view of the firewall of FIG. 2 anelectric vehicle according to embodiments.

FIG. 7 stiffening element to protect against a side or frontal impactfor an electric vehicle according to embodiments.

FIG. 8 depicts a front impact system according to embodiments.

FIG. 9 is a flowchart depicting a method for stiffening an electricvehicle to protect against a side or frontal impact according toembodiments.

DETAILED DESCRIPTION OF THE INVENTION

The subject matter of embodiments of the present invention is describedhere with specificity to meet statutory requirements, but thisdescription is not necessarily intended to limit the scope of theclaims. The claimed subject matter may be embodied in other ways, mayinclude different elements or steps, and may be used in conjunction withother existing or future technologies. This description should not beinterpreted as implying any particular order or arrangement among orbetween various steps or elements except when the order of individualsteps or arrangement of elements is explicitly described.

The systems and methods described herein relate generally toimprovements for electric vehicles. Due to the size and weightconsiderations of the batteries required to power such vehicles, as wellas the need to make electric vehicles as safe as possible, eachcomponent within the electric vehicles must be designed with particularcharacteristics in mind. Specifically, considerations related to theweight and structural integrity of each component must be weighed toensure that the electric vehicles are both efficient and safe tooperate. For example, the body of the vehicle must be stiff, efficient,and lightweight. A lightweight body helps counteract the additionalweight of the batteries, which may be in the form of several largebatteries, or numerous (sometimes thousands) of smaller batteries wiredtogether. The stiff body helps make the vehicle more stable duringcornering and also helps limit damage to the body and batteries during acollision. Protection of the batteries during a collision is particularimportant, as the large number of batteries pose a significant firehazard and may also expose passengers and others to highly corrosivematerial. Due to this high safety risk, it is imperative that the bodystructure be designed to withstand high force collisions from anydirection.

Turning now to FIG. 1, one embodiment of an electric vehicle 100 isshown. While shown here as an electric automobile, electric vehicle 100may be any motorized vehicle that is powered by electricity. Forexample, electric vehicle 100 may include vehicles such as cars, buses,trains, trucks, trams, watercraft, aircraft, and/or any other type oftransportation mechanism.

Here, much of the main body 102 of the electric vehicle 100, especiallythose components designed to form the skeleton of the vehicle and thosecomponents used for collision protection, are made of aluminum or alloyscontaining aluminum, although it will be appreciated that othermaterials may be considered. Aluminum alloys provide strong, yetlightweight components that help shed weight to compensate for the highweight of the batteries necessary to power the electric vehicle. Forelectric vehicles, an increased emphasis is placed on protection of thebatteries as damage to battery cells can cause explosion and fireswithin the vehicle. Such problems are compounded due to the large amountof space batteries must occupy within electric vehicles in order tomaintain practical driving ranges. Therefore, vehicle alterations thatprovide increased protection along edges and corners of the vehiclebattery are advantageous. Such alterations may include considerationsrelated to, but not limited to providing: (1) increased rigidity of thevehicle, (2) increased absorption of energy from a collision, and (3)increased efficiency of transfer of energy/force stemming from an impactto the vehicle's body to lessen the potential impact applied to thevehicle battery and to passengers in the vehicle.

Battery elements 104 (shown in FIG. 4) are positioned underneath a floorstructure 106 of the electric vehicle 100. Such positioning providesseveral benefits. First, the battery elements are isolated from thepassenger compartment, largely by an aluminum (or other metallicmaterial) floor structure 106, which helps increase passenger safety.The placement of the battery elements 104 underneath the vehicle 100also allows the battery elements 104 to be connected to electricalsystems of the vehicle 100 from underneath the floor structure 106. Thisenables the battery elements 104 to be changed out from the exterior ofthe vehicle 100. For example, the vehicle 100 may be raised up and thebattery elements 104 may be decoupled from the underside of the vehicle100. As just one example, a number of bolts or other fasteners may beremoved and the battery elements 104 may be lowered from the vehicle100. The battery elements 104 may be disconnected and new batteryelements 104 may be connected and fastened to the underside of thevehicle 100. This allows old batteries to be replaced easily, and alsoenables a quick swap of depleted battery elements 104 for chargedbattery elements 104, serving as a method of rapidly charging thevehicle 100 for longer trips. The placement of the battery elements 104also places much of the weight of the vehicle 100 near the ground, thuslowering the center of gravity of the vehicle 100, which allows thevehicle 100 to corner better and reduces the odds of a rollover.

Unlike automobiles that utilize internal combustion engines and includedrivetrains that extend along a length of the vehicle, electric vehicle100 is driven by one or more electric motors positioned near the wheelaxles. As a result, there is no need for a longitudinal drive train. Tohelp isolate a passenger compartment 108 from the battery elements 104while providing access for connections of the battery elements 104 to beconnected to electric systems within the passenger compartment 108 andto the one or more electric motors, the passenger compartment may beprovided with a rigid tunnel 110 protruding upward from a floorstructure 106 of the passenger compartment 108. However, unlike inconventional gas-powered vehicles where a tunnel may be provided toprovide clearance for a drivetrain, rigid tunnel 110 is included toprovide clearance for a portion of the battery elements 104 used tosupply power to the electric vehicle 100. The rigid tunnel 110 may notonly provide a housing for a portion of the battery assembly, but mayserve a number of other functions. As just one example, the rigid tunnel110 may help absorb and transfer force away from passengers in the eventof a collision. In such embodiments, the rigid tunnel 110 may be formedof carbon fiber or another composite material that is extremely strongand lightweight. In other embodiments, the rigid tunnel 110 may serve aspart of an air ventilation system, with hot or cold air being vented tothe passenger compartment 108 through a portion of the rigid tunnel 110.

FIG. 2 depicts one embodiment of a power system of the electric vehicle100. The power system may include a firewall 112 positioned between amotor compartment and a passenger compartment 108 of the electricvehicle 100. The firewall 112 may be formed of several components. Forexample, the firewall 112 may include a front cross beam 114 having aleft portion 116 and a right portion 118 separated by a medial portion148 extending there between. The left portion 116 and the right portion118 may each be bent rearward relative to the medial portion 148, thusdefining a foot well or other front portion of the passenger compartment108. For example, the left portion 116 and the right portion 118 may bebent backward at an angle of between about 10 and 40 degrees, moretypically between about 25 and 35 degrees, relative to the medialportion 148. The front cross beam 114 may have a generally rectangularcross-section that defines an open interior. In some embodiments, theopen interior may include a number of ribs that extend along a length ofthe front cross beam 114, as better shown in FIG. 6. The firewall 112may also include an angled portion 122 of the floor structure 106. Ahorizontal flat portion 150 of floor structure 106 may be coupled withand/or extend rearward from the firewall 112. The flat portion 150 maydefine an aperture 152 between the firewall 112 and one or more centralsupport beams 132 of the floor structure 106. The angled portion 122 maybe coupled with a bottom end of the front cross beam 114. Such couplingis further described in relation to FIG. 6.

In some embodiments, a left longitudinal support beam 124 may be coupledwith the left portion 116 and/or the angled portion 122 of the floorstructure 106. A right longitudinal support beam 126 may be coupled withthe right portion 118 and/or the angled portion 122 of the floorstructure 106. A right front crash beam 130 may be coupled with themedial portion 148 and/or the right portion 118 and may be generallyorthogonal to a right end of the medial portion 148. A left front crashbeam 128 may be coupled with the medial portion 148 and/or the leftportion 116 and may be generally orthogonal to a left end of the medialportion 148. In some embodiments, the crash beams 128 and 130 may becoupled directly with the front cross beam 114, while in otherembodiments the crash beams 128 and 130 may be coupled with the frontcross beam 114 via crash elements 154.

In some embodiments, the firewall 112 may be coupled with the rigidtunnel 110, which may extend rearward from the firewall 112 to one ormore central cross beams 132 as shown in FIG. 3. For example, a frontedge of the rigid tunnel 110 may be coupled with a medial portion of theangled portion 122 and a medial portion of the front cross beam 114. Thefront edge of the rigid tunnel 110 may be open, such that access to themotor compartment may be provided underneath the rigid tunnel 110. Arear portion of the rigid tunnel 110 may be coupled with the centralcross beams 132. For example, a forward most of the central cross beams132 may be coupled with an underside of the rigid tunnel 110, such aswithin a notch in the rigid tunnel 110 that is configured to receive theforward most central cross beam 132. The rearmost central cross beam 132may be configured to couple with and/or near a rear edge of the rigidtunnel 110. The central cross beams 132 may extend laterally across awidth of the passenger compartment 108. In some embodiments, a topsurface of one or more of the central cross beams 132 may be configuredto be used as mounting points for the front seats. For example, the topsurface of one of more of the central cross beams 132 may defineapertures that are configured to receive bolts and/or other fasteningmechanisms for coupling seat rails 164 and/or other seat mounts to thecentral cross member(s) 132. In some embodiments, seat brackets may bemounted to one or more of the central cross beams 132. These bracketsmay then receive seat rails 164 with which seats may be mounted.Oftentimes, each seat will be mounted to two seat rails 164, although itwill be appreciated that other numbers of rails 164 may be used.

In some embodiments, the central cross beams 132 (as well as othersupport members secured to the floor structure 106, as well as the floorstructure 106 itself) may be configured to have the battery assembly 104mounted thereon. For example, a lower surface of one or more of thecentral cross beams 132 may be configured to receive one or moreremovable fastening mechanisms, such as bolts, that are used to securethe battery assembly 104 to an underside of the floor structure 106. Asjust one example, the central cross beams 132 may be positioned atop thefloor structure 106, with the battery element 104 positioned against anunderside of the floor structure 106 (possibly with one or moreintervening layers and/or components between the battery element 104 andthe floor structure. One or more bolts may extend from an underside ofthe battery element 104, through the floor structure 106, and into aninterior of one or more of the central cross beams 132. The bolts orother fasteners may be positioned through apertures in the batteryelement 104 and/or a flange of the battery element 104. The centralcross beams 132 provide strong mounting locations for the batteryelement 104, allowing the battery element 104 to be larger and providethe vehicle 100 with a longer range.

The central cross beams 132 may also serve to strengthen the sides ofthe passenger compartment 108 and to protect the passenger compartment108 in the event of an impact. The front cross beam 114 (and rest offirewall 112) may be configured to transfer force from a frontalcollision from the front crash beams 128 and 130 to the one or morecentral cross beams 132 via the rigid tunnel 110. Additionally oralternatively, the front cross beam 114 (and rest of firewall 112) mayalso be configured to transfer force from a frontal collision from thefront crash beams 128 and 130 to the left longitudinal support beam 124and the right longitudinal support beam 126.

Battery assembly 104 may be configured to mount with an underside of thefloor structure 106. The battery assembly 104 may include at least onebattery 162, but often includes a large number of batteries ranging fromdozens to thousands, depending on the size of each of the batteries. Insome embodiments, the battery 162 includes a number of battery unitsarranged in two tiers as best seen in FIG. 4. For example, a first tiermay extend underneath all or part of the passenger compartment 108,while a second tier may be stacked upon a portion of the first tier suchthat it extends upward at a position rearward of the passengercompartment 108. In some embodiments, the upper tier of the batteryassembly 104 may be positioned rearward of a rear cross beam 204. Rearcross beam 204 may extend across a width of the passenger compartment108. The rear cross beam 204 may be configured to receive one or morefasteners configured to secure the battery assembly 104 to the undersideof the vehicle 100. In some embodiments, the rear cross beam 204 mayalso be used to mount one or more rear seats within the passengercompartment 108.

The battery assembly 104 may also include a battery connector housing156. The battery connector housing 156 may be configured to house atleast one battery connector therein. The battery connector housing 156may define at least one electric connector configured to couple with atleast one electric system of the electric vehicle 100, such as theelectric motor. The battery connector housing 156 may be configured tobe inserted within the aperture 152 of the floor structure 106 such thatat least a portion of the battery connector housing 156 extends above atop surface of the floor structure 106. This allows the electricconnectors to be accessible through a front opening of the rigid tunnel110, enabling the battery element 104 to be electrically coupled to boththe motor and the other electrical systems of the vehicle 100. Batteryassembly 104 may be secured to the underside of the floor structure 106using fasteners accessible from the underside of the floor structure 106such that the battery assembly 104 is removable from the electricvehicle 100 without accessing the passenger compartment 108. Thesefasteners may be spaced apart along the underside of the vehicle 100 atthe floor structure 106, central cross beams 132, a subfloor cross beam144, and/or other structural elements, with a spacing and number offasteners being determined by a weight, size, and/or shape of thebattery element 104.

Rigid tunnel 110 may be coupled with the firewall 112, such as at a rearsurface of the firewall 112. The rigid tunnel 110 may also be coupledwith the floor structure 106 and the central support beams 132. Therigid tunnel 110 may be configured to cover the portion of the batteryconnector housing 156 that extends above the floor structure 106 suchthat the passenger compartment 108 is sealed from the battery connectorhousing 156. In some embodiments, the rigid tunnel 110 has a crosssectional profile that generally matches a profile of the batteryconnector housing 156 as shown in FIG. 5. As seen here, the rigid tunnel110 may include extra space above the battery connector housing 156. Insuch embodiments, the extra space may be used to for additionalfeatures. For example, in one embodiment, the extra space may be used toprovide a conduit for the air conditioner and heating system. In someembodiments, the floor structure 106 includes a sealing element (notshown) protruding upward and contacting an inner surface of the rigidtunnel 110 between the battery connector housing 156 and the centralsupport beams 132. The sealing element may have a shape corresponding tothe rigid tunnel 110. This sealing element may further insulate thepassenger compartment 108 from the battery element 104, especially asthe profile of the rigid tunnel 110 decreases in size at rearwardportions.

In some embodiments, the rigid tunnel 110 may be designed to transferfrontal impact away from occupants of the vehicle 100. For example, therigid tunnel 110 may be coupled with a rear surface of the front crossbeam 114 and a top surface of the angled medial section 142 of the floorstructure 106. Frontal impact forces received by the firewall 112 may betransferred through the rigid tunnel 110, which may transmit the forcesto one or more central crossbeams 132 positioned rearward of thefirewall 112. Such diversion of forces may ensure that a maximum amountof force is directed around occupants of the vehicle 100. To provide thestrength necessary to transfer the impact forces while limiting theamount of weight added, the rigid tunnel 110 may be formed from carbonfiber.

Because the battery element 104 is positioned under the rigid tunnel110, to ensure maximum safety of the passenger compartment 108, it maybe desirable to include an acid resistant and/or flame resistantmaterial to the rigid tunnel 110 to increase protection of the passengercompartment 108 in the event of battery damage, which may result inexposure to battery acid or flames. For example, the rigid tunnel 110may be formed from materials with strong resistance to flame and/oracid. In other embodiments, one or more surfaces of the rigid tunnel 110may be coated with an acid resistant and/or flame resistant material. Inparticular, a lower surface of the rigid tunnel 110 may be coated toprotect against direct exposure to a damaged battery. In otherembodiments, a separate acid and/or fire resistant material may becoupled with an underside of the rigid tunnel 110. Additionally, due tothe rigid tunnel 110 being configured to cover a hole in the floorstructure 106 that enables the battery connector housing 156 to extendupward above the floor structure 106, the rigid tunnel 110 may includethermal insulation and/or acoustic insulation, as such insulation maynot be included on the battery element 104. This allows road noise, aswell as thermal effects from the environment and/or the battery element104 to be reduced within the passenger compartment 108.

FIG. 6 shows a cross-sectional view of the firewall 112 of FIG. 2. Asshown here, firewall 112 is formed from the junction of the front crossbeam 114 and the angled portion 122 of the floor structure 106. As notedabove, the firewall 112 defines a front portion of the passengercompartment 108, such as a passenger and/or driver foot well andseparates the passenger compartment 108 from a motor compartment of theelectric vehicle 100. As shown here, the firewall 112 includes frontcross beam 114 having left portion 116, right portion, 118, and medialportion 184 extending between the left portion 116 and right portion118, which may be bent rearward relative to the medial portion 184.Front cross beam 114 may define an interior including a number of ribs134 that extend along a length of the front cross beam 114. For example,at least two ribs 134 may extend from a front wall of the front crossbeam 114 to a rear wall of the front cross beam 114. The front crossbeam 114 may have a generally rectangular cross-section. The ribs 134may be positioned at regular intervals as shown here, or may be spacedat irregular intervals. Here, two ribs 134 are spaced equidistant fromone another and the top and bottom of the front cross beam 114, formingthree rectangular chambers within the front cross beam 114. The use ofribs 134 helps stiffen and strengthen the front cross beam 114 withoutadding a substantial amount of material or weight, thereby allowing thefront cross beam 114 to handle larger impact forces in the event of acollision.

The firewall 112 may also include floor structure 106. Specifically,floor structure 106 may include an angled portion 122 that angles upwardfrom a base 136 of the floor structure 106 to form a portion of a frontfoot well of the passenger compartment 108. This angled portion 122 maybe coupled with a bottom end of the front cross beam 114. For example,the angled portion 122 may include at least one upper flange or mountinginterface 138 that is generally aligned with a vertical axis of thefirewall 112. The upper flanges 138 may be coupled with a bottom end ofthe front cross beam 114. For example, a front upper flange 138 may besecured against a front surface of the front cross beam 114 and a rearupper flange 138 may be secured against a rear surface of the frontcross beam 114 such that the front cross beam 114 is secured between thefront upper flange 138 and the rear upper flange 138. For example, thefront cross beam 114 may be inserted between the upper flanges 138 andsecured using one or more fasteners. The angled portion 122 may alsoinclude at least one lower flange or mounting interface 140 that isseparated from the upper flange 138 by an angled medial section 142 thatslopes downward from front to back. The lower mounting interface 140 mayinclude a front lower flange 140 configured to be fastened against afront surface of a subfloor cross beam 144 and a rear lower flange 140configured to be fastened against a top surface of the subfloor crossbeam 144.

In some embodiments, the angled medial section 142 of the floorstructure 106 includes one or more embossed features formed in a topsurface and/or a bottom surface of the angled medial section 142. Theangled medial section 142 may also include a number of ribs (not shown)extending from a top surface to a bottom surface of the angled medialsection 142. The ribs and/or embossed features may serve to furtherstrengthen the floor structure 106 without adding substantial materialand weight. The lower flange 140 may be generally aligned with ahorizontal axis of the firewall 112. The firewall 112 may also includesubfloor cross beam 144 positioned underneath the floor structure 106and coupled with the lower flange 140 such that the subfloor cross beam144 is spaced laterally rearward of the medial portion 184 of the frontcross beam 114. The subfloor cross beam 144 may define an interior thatincludes at least one rib 146 extending along a length of the subfloorcross beam 144. In some embodiments, rib 146 may extend between a frontcorner and a rear corner of the subfloor cross beam 144. For example,the rib 146 may extend from a front lower corner of the subfloor crossbeam 144 to a rear upper corner of the subfloor cross beam 144. This rib146 helps stiffen and strengthen the subfloor cross beam 144 withoutadding a substantial amount of material or weight. In some embodiments,the subfloor cross beam 144 may receive one or more fasteners forcoupling the battery assembly 104 to the underside of the vehicle 100.

Oftentimes, the firewall 112 may be formed entirely from aluminum. Forexample, the front cross beam 114 and the subfloor cross beam 144 may beformed of extruded aluminum, which makes it easier to form any ribsintegral with the beams to ensure maximum strength. In some embodiments,the angled portion 122 of the floor structure 106 (and the floorstructure 106 itself) may be formed from cast or pressed aluminum. Suchformation is more suited for producing the embossed features withinsurfaces of the floor structure 106 that increase the strength and/orstiffen the floor structure 106.

In some embodiments, a front surface of the firewall 112 is coupled withone or more front crash beams 128 and 130 as shown in FIG. 2. In someembodiments, the firewall 112 may be directly coupled to the front crashbeams 128 and 130, while in other embodiments, one or more components,such as a crash element 154, may be coupled between the front crashbeams 128 and 130 and the firewall 112. In the event of a frontalimpact, the firewall 112 may be configured to receive and absorb a forcetransferred from the front crash beams 128 and 130. The firewall 112 mayalso be configured to direct force away from passengers, such as bydirecting the force around the front seats to structural componentsdesigned to handle impact forces. For example, as described with regardto FIG. 2, ends of the firewall 112 may be coupled with longitudinalsupport beams 124 and 126 that extend along sides of the vehicle 100.Impact forces may be transferred to these longitudinal support beams 124and 126 to direct the main forces around the passenger compartment 108to protect occupants in the event of a collision.

The firewall 112 may also be coupled with the rigid tunnel 110. Forexample, the rigid tunnel 110 may be coupled with a rear surface of thefront cross beam 114 and a top surface of the angled medial section 142of the floor structure 106. Frontal impact forces received by thefirewall 112 may be transferred through the rigid tunnel 110, which maytransmit the forces to one or more central crossbeams (not shown)positioned rearward of the firewall 112. Such diversion of forces mayensure that a maximum amount of force is directed around occupants ofthe vehicle 100.

FIG. 7 depicts a stiffening element to protect against a side or frontalimpact for the electric vehicle 100. The system may include a frontcrash cross beam 306 extending across a front end of the electricvehicle 100. The front crash cross beam 306 may serve as a bumper orforwardmost impact element of the vehicle 100. For example, a nose ofthe body of vehicle 100 may be positioned immediately in front of andcover the front crash cross beam 306. In some embodiments, a first endand a second end of the front crash cross beam 306 bend backwardrelative to a medial portion of the front crash cross beam 306, therebyhelping to define a front end shape of the vehicle 100. The front crashcross beam 306 may have a generally rectangular cross-section having anouter periphery defined by a top wall 338, a front wall 340, a lowerwall 342, and a rear wall 344. In some embodiments, the outer peripheryof the front crash cross beam 306 may define an interior having one ormore ribs extending along a length of the front crash cross beam 306.For example, a rib 346 may extend horizontally between a center of thefront wall 340 a center of the rear wall 344. Rib 346 may make frontcrash cross beam 306 more rigid and allow the front crash cross beam 306to absorb a greater amount of impact force, as more force is needed tocrumple or otherwise bend the rib 316, along with the rest of the frontcrash cross beam 306. Rib 346 may have a thickness of between about 0-1cm to provide necessary strength while still keeping a weight of thefront crash cross beam 306 sufficiently low. While shown with a singlerib 346, it will be appreciated that any number of ribs may be includedwithin the interior of the front crash cross beam 306. These ribs may beprovided in any arrangement, however ribs extending either horizontallyor diagonally between the front wall 340 and the rear wall 344 providethe most resistance to front impacts.

To facilitate the formation of the ribs, the front crash cross beam 306may be extruded from aluminum such that any ribs are formed along withthe outer walls of the front crash cross beam 306. In some embodiments,connection points between the ribs and the outer walls of the frontcrash cross beam 306 may taper outward such that a thickness near theconnection point is greater than a thickness of the rest of the ribs.Similarly, junctions of the ribs with one another may also have greaterthicknesses than the rest of the ribs.

The front crash beams 128 and 130 may be coupled with a rear surface ofthe front crash cross beam 306. Oftentimes, the left front crash beam128 and right front crash beam 130 may be coupled to the medial portionof the front crash cross beam 306 such that the bent first end andsecond end are disposed laterally outward of the left front crash beam128 and right front crash beam 130, respectively. The front crash crossbeam 306 may be configured to transfer force from a front collision tothe left front crash beam 128 and/or the right front crash beam 130. Insome embodiments, each of the left front crash beam 128 and the rightfront crash beam 130 define an interior having one or more ribs tofurther strengthen the beam. Additionally, each of the front crash beams128 and 130 may include one or more dimples 318 formed in an outerperiphery of the crash beam. Oftentimes, the dimples 318 may be formedon corners of the crash beams 128 and 130 such that the dimples extendinto two side surfaces of the crash beams 128 and 130. Dimples 318 mayserve to encourage the front crash beams 128 and 130 to crumple in anaccordion-like manner in the event of a frontal impact to absorb as muchof the impact force as possible prior to transferring the forces back tothe firewall 112 and the other structural members of vehicle 100.

The system may also include firewall 112 that is configured to separatea passenger compartment of the electric vehicle from a motor compartmentor other forward portion of the electric vehicle 100. The firewall 112may be formed of several components. For example, the firewall 112 mayinclude a front cross beam 114 having a left portion 116 and a rightportion 118 separated by a medial portion 184 extending therebetween.The left portion 116 and the right portion 118 may each be bent rearwardrelative to the medial portion 184, thus defining a footwell or otherfront portion of the passenger compartment 108. For example, the leftportion 116 and the right portion 118 may be bent backward at an angleof between about 10 and 40 degrees, most commonly between about 25 and35 degrees, relative to the medial portion 184. The front cross beam 114may have a generally rectangular cross-section that defines an openinterior. In some embodiments, the open interior may include a number ofribs that extend along a length of the front cross beam 114. Thefirewall 112 may also include an angled portion 122 of the floorstructure 106. The angled portion 122 may be coupled with a bottom endof the front cross beam 114.

The system may further include a trunk 320 positioned between the leftfront crash beam 128 and the right front crash beam 130. The trunk 320may be positioned between the front crash cross beam 306 and thefirewall 112. The trunk 320 may define a storage compartment between thefront crash cross beam 306, the firewall 112, and the front crash beams128 and 130. In some embodiments, the trunk 320 may include a hingedtrunk hood (not shown) configured to control access to the storagecompartment.

Trunk 320 may include a trunk base 322 forming a floor of the trunk 320.The trunk 320 may also include one or more stiffening elementspositioned across one or both of a width or length of the trunk base 322to help strengthen the trunk 320 and to protect against side and/orfrontal impacts. For example, a support beam 324 may extend across awidth of the trunk base 322. The support beam 324 may be positionedproximate a rear wall 326 of the trunk 320. In some embodiments, thetrunk 320 includes a shelf 328 that extends from the rear wall 326. Theshelf 328 may be positioned across the width of the trunk 320, with thesupport beam 324 being positioned adjacent the rear wall 326. In someembodiments, one or more embossed ribs 348 and/or other embossedfeatures may be formed into and extend across one or both of a length orthe width of the trunk base 322.

In some embodiments, the support beam 324 defines an open interiorhaving a number of ribs 348 extending along a length of the support beam324. For example the support beam 324 may include a top wall 330, afront wall 332, a rear wall 334, and a bottom wall 336. The support beam324 may have a trapezoidal cross-section. For example, the top wall 330may have a greater length than the rear wall 334 such that the frontwall 332 and/or the bottom wall 336 must be angled to connect the topwall 330 and bottom wall 336. Ribs 348 may be provided to connect thevarious walls within the interior to provide enhanced strength andrigidity.

To facilitate the formation of the ribs, the support beam 324 may beextruded from aluminum such that any ribs are formed along with theouter walls of the support beam 324. In some embodiments, connectionpoints between the ribs and the outer walls of the support beam 324 maytaper outward such that a thickness near the connection point is greaterthan a thickness of the rest of the ribs. Similarly, junctions of theribs with one another may also have greater thicknesses than the rest ofthe ribs. In some embodiments, the trunk base 322 and support beam 324may be formed integral with one another, while in other embodiments thecomponents may be fabricated separately and later welded, fastened,and/or otherwise secured to one another.

FIG. 8 depicts a front impact system of the electric vehicle 100. Thesystem may include the front crash cross beam 306 having ends that bendbackward relative to a medial portion of the front crash cross beam 306extending across a front end of the electric vehicle 100. The frontcrash cross beam 306 may serve as a bumper or forwardmost impact elementof the vehicle 100. For example, a nose of the body of vehicle 100 maybe positioned immediately in front of and cover the front crash crossbeam 306. In some embodiments, a first end and a second end of beam 306are angled rearward from a medial portion of the beam 306, therebyhelping to define a front end shape of the vehicle 100. The front crashcross beam 306 may have a generally rectangular cross-section having anouter periphery defined by a top wall 338, a front wall 340, a lowerwall 342, and a rear wall 344. In some embodiments, the outer peripheryof the front crash cross beam 306 may define an interior having one ormore ribs extending along a length of the front crash cross beam 306.For example, a rib 346 may extend horizontally between a center of thefront wall 340 a center of the rear wall 344. Rib 346 may make frontcrash cross beam 306 more rigid and allow the front crash cross beam 306to absorb a greater amount of impact force, as more force is needed tocrumple or otherwise bend the rib 346, along with the rest of the frontcrash cross beam 306. Rib 346 may have a thickness of between about 0.1and 1 cm to provide necessary strength while still keeping a weight ofthe front crash cross beam 306 sufficiently low. While shown with asingle rib 346, it will be appreciated that any number of ribs may beincluded within the interior of the front crash cross beam 306. Theseribs may be provided in any arrangement, however ribs extending eitherhorizontally or diagonally between the front wall 340 and the rear wall344 provide the most resistance to front impacts.

To facilitate the formation of the ribs, the front crash cross beam 306may be extruded from aluminum such that any ribs are formed along withthe outer walls of the front crash cross beam 306. In some embodiments,connection points between the ribs and the outer walls of the frontcrash cross beam 306 may taper outward such that a thickness near theconnection point is greater than a thickness of the rest of the ribs.Similarly, junctions of the ribs with one another may also have greaterthicknesses than the rest of the ribs.

A left crash beam 128 and a right crash beam 130 may be coupled with arear surface of the front crash cross beam 306. Oftentimes, the leftcrash beam 128 and right crash beam 130 may be coupled to the medialportion of the front crash cross beam 306 such that the bent first endand second end are disposed laterally outward of the left crash beam 128and right crash beam 130, respectively. The front crash cross beam 306may be configured to transfer force from a front collision to the leftcrash beam 128 and/or the right crash beam 130. In some embodiments,each of the left crash beam 128 and the right crash beam 130 define aninterior having one or more ribs to further strengthen the beam. Asnoted above, dimples 318 may be provided on the crash beams 128 and 130to help the crash beams 128 and 130 deform in a most efficient manner toabsorb force in the event of a frontal impact.

Front cross beam 114 may be coupled with a rear end of each of the leftcrash beam 128 and the right crash beam 130. The front cross beam 114may form a portion of firewall 112 that is configured to separate thepassenger compartment 108 from a motor compartment of the electricvehicle 100. The front cross beam 114 and/or other firewall componentsmay be configured to direct force from the front collision away from thepassenger compartment 108 such as by directing forces through one ormore longitudinal support beams extending along the sides of the vehicle100 and/or to one or more central cross beams via the rigid tunnel 110.

FIG. 9 is a flowchart depicting a process 900 for stiffening an electricvehicle to protect against a side or frontal impact for an electricvehicle. Process 900 may be performed using the electric vehicle 100described herein. Process 900 may begin at block 902 by positioning atrunk between a left longitudinal crash beam and a right longitudinalcrash beam of the electric vehicle. For example, the trunk may bepositioned forward of a firewall and rearward of a front bumper.

The trunk may define a storage compartment between the support beams,forward of a firewall of the electric vehicle, and behind a front crossbeam of the electric vehicle. The trunk may include a trunk base forminga floor of the trunk. At block 904, a trunk support beam may bepositioned across a width of the trunk base such that a first end of thetrunk support beam contacts the left longitudinal support beam and asecond end of the trunk support beam contacts the right longitudinalsupport beam. The trunk support beam may be configured to stiffen thetrunk in the event of a side impact. In some embodiments, the supportbeam has a trapezoidal cross-section defined by a top wall, a frontwall, a rear wall, and a bottom wall, with the top wall having a greaterlength than the rear wall of the support beam. In some embodiments, theouter walls of the trunk support beam define an open interior thatincludes a number of ribs extending along a length of the support beam.The trunk base may also include one or more embossed ribs and/or otherembossed features extending across one or both of a length or the widthof the trunk base to help stiffen the trunk and to protect againstcollision forces. In some embodiments, positioning the trunk supportbeam may include securing or forming the trunk support beam against atrunk shelf extending from a rear wall of the trunk. For example, thetrunk support beam may be formed integral with the trunk base and/or thetrunk shelf. In other embodiments, the trunk support beam may be formedseparately from the rest of the trunk and later fastened, welded, and/orotherwise secured to the trunk base and the trunk shelf.

It should be noted that the systems and devices discussed above areintended merely to be examples. It must be stressed that variousembodiments may omit, substitute, or add various procedures orcomponents as appropriate. Also, features described with respect tocertain embodiments may be combined in various other embodiments.Different aspects and elements of the embodiments may be combined in asimilar manner. Also, it should be emphasized that technology evolvesand, thus, many of the elements are examples and should not beinterpreted to limit the scope of the invention.

Specific details are given in the description to provide a thoroughunderstanding of the embodiments. However, it will be understood by oneof ordinary skill in the art that the embodiments may be practicedwithout these specific details. For example, well-known structures andtechniques have been shown without unnecessary detail in order to avoidobscuring the embodiments. This description provides example embodimentsonly, and is not intended to limit the scope, applicability, orconfiguration of the invention. Rather, the preceding description of theembodiments will provide those skilled in the art with an enablingdescription for implementing embodiments of the invention. Variouschanges may be made in the function and arrangement of elements withoutdeparting from the spirit and scope of the invention.

Having described several embodiments, it will be recognized by those ofskill in the art that various modifications, alternative constructions,and equivalents may be used without departing from the spirit of theinvention. For example, the above elements may merely be a component ofa larger system, wherein other rules may take precedence over orotherwise modify the application of the invention. Also, a number ofsteps may be undertaken before, during, or after the above elements areconsidered. Accordingly, the above description should not be taken aslimiting the scope of the invention.

Also, the words “comprise”, “comprising”, “contains”, “containing”,“include”, “including”, and “includes”, when used in this specificationand in the following claims, are intended to specify the presence ofstated features, integers, components, or steps, but they do notpreclude the presence or addition of one or more other features,integers, components, steps, acts, or groups.

1. (canceled)
 2. A stiffening element to protect against a side orfrontal impact for an electric vehicle, comprising: a crash cross beam;a first crash beam coupled with and extending rearward from the crashcross beam; a second crash beam coupled with and extending rearward fromthe crash cross beam; and a trunk positioned between the first crashbeam and the second crash beam, the trunk being positioned inward of thecrash cross beam, wherein the trunk comprises a support beam thatextends across a width of the trunk.
 3. The stiffening element toprotect against a side or frontal impact for an electric vehicle ofclaim 2, wherein: each of the first crash beam and the second crash beamcomprise at least one dimple that is configured to cause the respectivecrash beam to crumple in an accordion-like manner in an event of afrontal impact.
 4. The stiffening element to protect against a side orfrontal impact for an electric vehicle of claim 2, wherein: the crashcross beam comprises a medial portion, a first end, and a second end;and the first end and the second end are bent reward relative to themedial portion.
 5. The stiffening element to protect against a side orfrontal impact for an electric vehicle of claim 2, wherein: the supportbeam is positioned adjacent a rear wall of the trunk.
 6. The stiffeningelement to protect against a side or frontal impact for an electricvehicle of claim 2, further comprising: a firewall positioned rearwardof the trunk and coupled with rear ends of the first crash beam and thesecond crash beam.
 7. The stiffening element to protect against a sideor frontal impact for an electric vehicle of claim 6, wherein: thefirewall is coupled with the rear ends of the first crash beam and thesecond crash beam via one or more crash elements.
 8. A stiffeningelement to protect against a side or frontal impact for an electricvehicle, comprising: a first crash beam coupled positioned on a firstlateral side of the electric vehicle; a second crash beam coupledpositioned on a second lateral side of the electric vehicle; and a trunkpositioned between the first crash beam and the second crash beam, thetrunk comprises a support beam that extends across a width of the trunk,wherein the support beam is positioned proximate a rear wall of thetrunk.
 9. The stiffening element to protect against a side or frontalimpact for an electric vehicle of claim 8, wherein: the trunk furthercomprises a shelf that extends from a rear wall of the trunk.
 10. Thestiffening element to protect against a side or frontal impact for anelectric vehicle of claim 9, wherein: the shelf comprises the supportbeam.
 11. The stiffening element to protect against a side or frontalimpact for an electric vehicle of claim 8, wherein: the support beamcomprises a front wall, a rear wall, a top wall, and a bottom wall. 12.The stiffening element to protect against a side or frontal impact foran electric vehicle of claim 11, wherein: the support beam comprises arib that extends from a front of the top wall to a rear of the bottomwall.
 13. The stiffening element to protect against a side or frontalimpact for an electric vehicle of claim 11, wherein: the support beamcomprises a trapezoidal cross section; and the rear wall slopes rearwardfrom a bottom of the rear wall to a top of the rear wall.
 14. Thestiffening element to protect against a side or frontal impact for anelectric vehicle of claim 8, wherein: the support beam is positionedwithin an interior of the trunk.
 15. A method of stiffening an electricvehicle to protect against a side or frontal impact for an electricvehicle, the method comprising: positioning a trunk between a firstcrash beam and a second crash beam of the electric vehicle, the trunkdefining a storage compartment inward of a crash cross beam of theelectric vehicle; and positioning a trunk support beam across a width ofthe trunk, the trunk support beam being configured to stiffen the trunkin an event of a side impact, wherein the trunk support beam ispositioned proximate a rear wall of the trunk.
 16. The method ofstiffening an electric vehicle to protect against a side or frontalimpact for an electric vehicle of claim 15, wherein: positioning thetrunk support beam comprises securing or forming the trunk support beamagainst a trunk shelf extending from a rear wall of the trunk.
 17. Themethod of stiffening an electric vehicle to protect against a side orfrontal impact for an electric vehicle of claim 15, wherein: the supportbeam comprises a front wall, a rear wall, a top wall, a bottom wall, anda rib that extends from the top wall to the bottom wall.
 18. The methodof stiffening an electric vehicle to protect against a side or frontalimpact for an electric vehicle of claim 15, wherein: the crash crossbeam comprises a generally rectangular cross section and includes atleast one rib formed within an interior of the crash cross beam.
 19. Themethod of stiffening an electric vehicle to protect against a side orfrontal impact for an electric vehicle of claim 15, wherein: the firstcrash beam and the second crash beam are coupled with a firewall of theelectrical vehicle.
 20. The method of stiffening an electric vehicle toprotect against a side or frontal impact for an electric vehicle ofclaim 19, wherein: the trunk is formed between the crash cross beam andthe firewall.
 21. The method of stiffening an electric vehicle toprotect against a side or frontal impact for an electric vehicle ofclaim 15, wherein: the trunk is formed in a portion of the electricvehicle that is forward of a passenger compartment of the electricvehicle.